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KAESER
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ASD 40
KAESER ASD 40 Service Manual
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Service Manual
Screw Compressor
ASD T
Tri-Voltage
9_5721 06 USE
2
Table of Contents
Table of Contents
3
Regarding this Document Using the Document
11
Additional Documents
11
Copyright
11
Symbols and Identification
11
Warnings
11
Other Instructions and Symbols
12
Tab. 1 the Levels of Danger and Their Meaning
12
Technical Data Nameplate
13
Options
13
Tab. 2 Nameplate
13
Weight
14
Temperature
14
Ambient Conditions
14
Tab. 3 Options
14
Tab. 4 Machine Weight
14
Tab. 5 Temperature
14
Tab. 6 Ambient Conditions
14
Ventilation
15
Pressure
15
Fig. 1 Maximum Relative Humidity
15
Tab. 7 Ventilation
15
Tab. 8 Safety Relief Valve Setting
15
Delivery
16
Cooling Oil Recommendation
16
Basic Information
16
KAESER Lubricants
16
Tab. 9 Delivery
16
Cooling Oil Volume
17
Tab. 10 Cooling Oil Charge
17
Tab. 11 Cooling Oil Charge (Option W1)
17
Tab. 12 Cooling Oil Charge (Option W2)
17
Motors and Power
18
Drive Motor
18
Fan Motor
18
Sound Pressure Level
18
Tab. 13 Cooling Oil Charge (Option W3)
18
Tab. 15 Drive Motor Rated Speed
18
Tab. 16 Fan Motor
18
Power Supply
19
Power Supply Specifications
19
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral
19
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral
19
Tab. 17 Sound Pressure Level
19
Heat Recovery
20
Prepared for External Heat Recovery
20
Tab. 18 Supply 208V/3/60Hz
20
Tab. 19 Supply 230V/3/60Hz
20
Tab. 20 Supply 460V/3/60Hz
20
Tab. 21 Heat Capacity (Option W1)
20
Internal Heat Recovery
21
Tab. 22 Water Quality Specification
21
Tab. 23 Heat Exchanger Specification (Option W2/W3)
21
Refrigeration Dryer
22
Tab. 24 Heat Capacity (Option W2/W3)
22
Tab. 25 Flow Rate (Option W2)
22
Tab. 26 Flow Rate (Option W3)
22
Tab. 27 Refrigeration Dryer: Model
22
Tab. 28 Refrigeration Dryer: Compressed Air System
23
Tab. 29 Refrigeration Dryer: Refrigeration Circuit
23
Safety and Responsibility Basic Information
24
Specified Use
24
Improper Use
24
User's Responsibilities
24
Observe Statutory and Universally Accepted Regulations
24
Qualified Personnel
25
Adhere to Inspection Schedules and Accident Prevention Regulations
25
Dangers
25
Safely Dealing with Sources of Danger
26
Safe Machine Operation
28
Organizational Measures
28
Danger Areas
28
Safety Devices
29
Safety Signs
29
Tab. 30 Danger Areas
29
Fig. 4 Location of Safety Signs
30
In Emergency
31
Fire Fighting
31
Tab. 31 Safety Signs
31
Remove any Compressor Cooling Oil from Your Person
32
Injury from Handling Refrigerant
32
Warranty
32
Environmental Protection
33
Design and Function
34
Enclosure
34
Functional Description of the Machine
34
Fig. 5 Enclosure
34
Fig. 6 Machine Layout
35
Refrigeration Dryer
36
Floating Relay Contacts
36
Options
36
Machine Mountings
36
Fig. 7 Refrigeration Dryer
36
Fig. 8 Machine Mountings
36
Cooling Air Filter Mat
37
Heat Recovery
37
Optional Filter Monitoring Set
37
Fig. 9 Cooling Air Filter Mat (Option K3)
37
Fig. 10 Internal Heat Recovery (Option W2/W3)
37
Operating States and Control Modes
38
Operating States of the Machine
38
Control Modes
38
Refrigeration Dryer Control Modes
39
Tab. 32 Operating States under MODULATING Control
39
Tab. 33 Refrigeration Dryer Control Modes
39
Safety Devices
40
SIGMA CONTROL Keys and Indicators
40
Fig. 11 Keys
40
Fig. 12 Indicators
41
Tab. 34 Keys
41
Tab. 35 Indicators
41
Installation and Operating Conditions
42
Safety
42
Installation Conditions
42
Place of Installation and Distances
42
Ensure Adequate Ventilation
43
Exhaust Duct Design
43
Fig. 13 Recommended Installation and Dimensions [Inch]
43
Using the Compressor to Supply a Compressed Air System
44
Installation Safety
45
Reporting Transport Damage
45
Making the Compressed Air Connection
45
Connecting the Condensate Drain
46
Fig. 14 Compressed Air Connection
46
Fig. 15 Condensate Drain Dimensions [Inch]
46
Making the Power Supply Connection
47
Changing Main Voltage Connections
47
Tab. 36 Voltage Selection
47
Tab. 14 Drive Motor
48
Tab. 37 Overload Protection Relay Settings
48
Tab. 38 Motor Protection Switch Settings
48
Refrigeration Dryer: Connecting the Transformer According to the Power Supply
49
Options
49
Anchoring the Machine
49
Initial Start-Up Safety
50
To be Noted before Commissioning
50
Checking Installation and Operating Conditions
51
Tab. 39 Re-Commissioning after Storage
51
Tab. 40 Installation Conditions Checklist
51
Setting the Overload Protection Cut-Out
52
Setting the Motor Overload Protection Switch
52
Pouring Cooling Oil into the Airend
52
Fig. 16 Inlet Valve Filling Port
52
Check Direction of Rotation
53
Starting the Machine for the First Time
53
Fig. 17 Coupling
53
Setting the Setpoint Pressure
54
Changing the Display Language
54
Fig. 18 Label: Changing the Display Language
55
Operation
56
Switching on and off
56
Switching on
56
Shutdown
56
Fig. 19 Switching on and off
56
Switching off in an Emergency and Switching on Again
57
Remote on and off Switching
57
Fig. 20 Switching off in an Emergency
57
Switching on and off with the Clock
58
Fig. 21 Switching on and off in Remote
58
Tab. 41 Machine Identification
58
Tab. 42 Remote Control Identification
58
Acknowledging Alarm and Warning Messages
59
Fig. 22 Switching on and off with the Clock
59
Tab. 43 Machine Identification
59
Fig. 23 Acknowledging/Resetting Messages
60
Fault Recognition and Rectification
61
Basic Information
61
Alarm Messages (Machine Shut-Down)
61
Tab. 44 Alarm Messages and Measures
61
Warning Messages (Yellow LED Lights)
64
Other Faults
68
Tab. 45 Warning Messages
68
Tab. 46 Other Faults and Actions
69
10.1 Maintenance
70
Safety
70
Maintenance Schedule
70
Logging Maintenance Work
70
Resetting Maintenance Interval Counters
71
Regular Maintenance Tasks
71
Tab. 47 Regular Maintenance Tasks
71
Cooling Oil Changing Interval
72
Regular Service Work
72
Tab. 48 Oil Change Intervals Lubricants
72
Cooler: Cleaning or Renewing the Filter Mats
73
Fig. 24 Filter Mat for the Air and Oil Cooler
73
Tab. 49 Regular Service Work
73
Cleaning or Replacing the Control Cabinet Filter Mats
74
Cooler Maintenance
74
Fig. 25 Control Cabinet Ventilation Grill
74
Heat Recovery System Maintenance
75
Fig. 26 Cleaning the Cooler
75
External Heat Recovery
76
Internal Heat Recovery
76
Air Filter Maintenance
76
Motor Maintenance
77
Fig. 27 Air Filter Maintenance
77
Checking the Coupling
78
Fig. 28 Checking the Coupling
78
Checking the Safety Relief Valve
79
Checking the Overheating Safety Shutdown Function
79
Checking the Cooling Oil Level
79
Venting the Machine (Depressurizing)
80
Fig. 29 Checking the Cooling Oil Level
80
Fig. 30 Venting the Machine
81
Topping up the Cooling Oil
82
Venting the Machine (Depressurizing)
82
Fig. 31 Topping up the Cooling Oil
82
Top up with Cooling Oil and Test Run
83
Changing the Cooling Oil
84
Fig. 32 Changing the Cooling Oil, Oil Separator Tank
85
Fig. 33 Changing the Cooling Oil, Oil Cooler
86
Fig. 34 Changing the Cooling Oil, Airend
87
Changing the Oil Filter
88
Fig. 35 Changing the Cooling Oil, Heat Recovery System
88
Changing the Oil Separator Cartridge
89
Fig. 36 Changing the Oil Filter
89
Fig. 37 Changing the Oil Separator Cartridge
90
Refrigeration Dryer Maintenance
91
Cleaning the Refrigerant Condenser
91
Fig. 38 Refrigeration Dryer
91
Checking Condensate Drainage
92
Condensate Drain Maintenance
92
Fig. 39 Checking Condensate Drainage
92
Fig. 40 Condensate Drain Maintenance
93
Document Maintenance and Service Work
94
Tab. 50 Logged Maintenance Tasks
94
11 Spares, Operating Materials, Service
95
Note the Nameplate
95
Ordering Consumable Parts and Operating Materials
95
Sigma Air Service
95
Tab. 51 Consumable Parts
95
Service Addresses
96
Spare Parts for Service and Repair
96
12 Decommissioning, Storage and Transport
99
Putting out of Operation
99
Packing
99
Storage
99
Transporting
100
Safety
100
Transporting with a Forklift
100
Transporting with a Crane
100
Fig. 41 Transporting with a Forklift
100
Disposal
101
Fig. 42 Transporting with a Crane
101
13 Annex
102
Pipeline and Instrument Flow Diagram (P+I Diagram)
102
5
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KAESER ASD 40 Specifications
General
Model
ASD 40
Category
Compressor
Motor Power
22 kW
Sound Level
69 dB(A)
Voltage
400 V
Frequency
50 Hz
Type
Rotary Screw Compressor
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